System and apparatus for routing a wire rope or wireline

ABSTRACT

An apparatus of this disclosure provides a twisted- or 3-dimensional guide path for a wire rope or wireline, the guide path being defined by a plurality of sheaves arranged sequentially along the path with the wrap angle being on a same side portion of each sheave as any other sheave of the plurality. The guide path may start at a first sheave having a center point at (X, Y, Z) n  and may end at a last sheave having a center point at (X, Y Z) N , N being the total number of sheaves of the guide path. Unlike the prior art, the plurality of sheaves does not need to follow a linear path defined by alignment with a wire rope or wireline entry location to a piece of equipment. Because of the twisted guide path being provided, the apparatus can accommodate different locations of wireline entry around a top drive.

BACKGROUND

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

This disclosure relates to systems, apparatuses, and methods for inserting and routing wire rope or wireline for use in hoisting systems, hoisting and rotating systems, and drilling systems.

By way of example, in oil and gas drilling operations a wireline may be routed through a main shaft of a top drive system. The top drive system turns the drill string and includes one or more electric or hydraulic motors connected with appropriate gearing to a short section of pipe called a quill. The quill, in turn, may be screwed into a saver sub or the drill string itself. The top drive system is suspended from a hook so it is free to travel up and down the derrick. The wireline is routed in such a way that the top drive system can remain made-up relative to the drill string during lifting, lowering and rotation of the drill string.

To facilitate entry of the wireline into the wellbore, a top entry wireline apparatus is attached to the top drive system. Top entry wireline apparatuses generally consist of sheave and pulley systems, with the wireline entering through a top opening of a goose neck of the top drive. The entry location is usually in a confined, crowded space because the top drive's suspension systems (e.g., bails, traveling block, weight compensation system) are in that general location as well. Additionally, the sheave and pulley systems can be large and bulky. Therefore, the wireline must be routed or guided from outside of the top drive/travelling block envelope and into the well center/main shaft/gooseneck opening axis. See e.g., U.S. Pat. No. 4,899,816 A to Mine; U.S. Pat. No. 5,735,351 A to Helms.

Further, because modern wirelines carry several electrical conduits and are sensitive to bending radii, relatively large cable sheaves are used. These sheaves usually do not fit into the desired location. Because modern top drives systems are designed to be as compact as possible, many manufactures do not provide sufficient space above the gooseneck for arranging the wireline entry apparatus. At the same time, the wireline design becomes more sophisticated (e.g., more electrical conduits) and loaded (e.g., increased weight of the logging, jarring, and fishing equipment), wireline diameter increases, thereby requiring larger diameter sheaves (that do not fit even more).

More compact top entry line apparatuses have been designed that make use arc shaped segments with multiple small sheaves. See e.g., US 2015/0013992 A1 to Mann et al. However, small sheaves, even when configured as an arcuate segment, can introduce significantly higher contact stresses than a larger sheave, optimally sized for the wireline diameter. Excessive contact stresses introduce higher (partial) fatigue damage to the wireline at each cycle. Therefore, limiting the number of these small sheaves has an advantage, which the Mann et al. apparatus tries to accomplish. However, when used in connection with a top drive it still requires a certain amount of space available in a radial direction from the main shaft axis. This space is usually occupied by suspension components of the top drive or by its prime movers with blowers. Therefore, these compact designs, like the large cable sheave designs, still require a precise location for entry of the wireline around the top drive.

SUMMARY

This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining or limiting the scope of the claimed subject matter as set forth in the claims.

Embodiments of an apparatus of this disclosure provide a twisted- or 3-dimensional guide path for a wire rope or wireline. The guide path may include a housing containing a plurality of sheaves located between the proximal and distal ends of the housing and arranged sequentially along a longitudinal centerline of the housing. The sheaves have a centerline coaxial to an axis of rotation and an orientation in a plane perpendicular to the centerline. The sheaves further have a width sized to receive a predetermined wireline size and a diameter sized to provide a predetermined wrap angle α. In embodiments, the sheaves may have the same diameter. The planar orientation of each sheave S_(i+1) of the plurality of sheaves is at an oblique angle β relative to the planar orientation of sheave S_(i) of the plurality of sheaves, where i=1 to N, N being the total number of sheaves. Collectively, the sheaves “twist” through a total angle Nβ. Because the sheaves are located along a centerline of the housing, a portion of the housing also twists through the total angle Nβ. In embodiments, the proximal and distal ends of the housing may be located at different elevations. The centerlines of sheaves S_(i+1) and S_(i) may be at a different elevations relative to one another.

Other embodiments may include another sheave located upstream or downstream of the guide path or housing. This other sheave has a larger diameter and wrap angle than that of the plurality of sheaves. This sheave further has a centerline coaxial to an axis of rotation and an orientation in a plane perpendicular to the centerline. A wireline or wire rope may be routed from this larger sheave toward the proximal end of the guide or it may be routed from the distal end of the guide toward the larger sheave. The larger sheave may have a same or different planar orientation as that of sheave S₁ of the plurality of smaller diameter sheaves.

The apparatus may be configured as a top-entry wireline apparatus. By way of a non-limiting example, the apparatus may be connected to a top drive configured for lifting, lowering, and rotating drillstring. Because of the twisted guide path being provided, the apparatus can accommodate different locations of wireline entry around the top drive. Unlike the prior art, the plurality of sheaves does not need to follow a linear path defined by alignment with a wireline entry location to a piece of equipment.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject disclosure is further described in the following detailed description, and the accompanying drawing and schematic of non-limiting embodiment of the subject disclosure. The features depicted in the figure are not necessarily shown to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form, and some details of elements may not be shown in the interest of clarity and conciseness.

FIG. 1 is a schematic of a drilling system employing a top drive and wireline and routed through a main shaft of a top drive system.

FIG. 2 is right side elevation view of an embodiment of a top entry wireline apparatus of this disclosure and used in connection with a top drive system.

FIG. 3 is a front elevation view (partial) of an embodiment of the apparatus of FIG. 2.

FIG. 4 is an isometric view of an embodiment of an apparatus of this disclosure showing non-planar bending or routing of a wireline.

FIG. 5 is a view showing the non-planar bending and routing of the wireline in the X-Z plane.

FIG. 6 is view showing the non-planar bending and routing of the wireline in the X-Y plane.

FIG. 7 is an isometric view showing a 3-dimensional routing a wireline when an apparatus of this disclosure is used in connection with a top drive system.

FIG. 8 is a front elevation view illustrating a wrap angle α and an off-plane (twisting) angle β of this disclosure. Other wrap and twisting angles may be used where appropriate.

FIG. 9 is a cross-section view taken along section line 9-9 of FIG. 8.

FIG. 10 is a view showing an embodiment of a 3-dimensional routing of this disclosure.

FIG. 11 is a view showing of an embodiment of a contoured mounting plate or frame of this disclosure (in partial section).

ELEMENTS AND NUMBERING USED IN THE DRAWINGS

-   10 Wire rope or wireline apparatus -   20 Housing -   21 Central longitudinal centerline 21 of the housing 20 between the     proximal and distal ends -   23 Frame -   25 Sidewalls -   27 Top or bottom end -   31 Distal end -   40 Smaller diameter sheaves -   41 Axis of rotation -   43 Pin -   45 Centerline -   60 Larger diameter sheave -   61 Axis of rotation -   63 Pin -   P Guide path -   S Sheave -   W Wire rope or wireline

DETAILED DESCRIPTION

One or more specific embodiments of the present disclosure will be described below. These described embodiments are only exemplary of the present disclosure. Additionally, in an effort to provide a concise description of these exemplary embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

Referring to the drawings, embodiments of an apparatus 10 of this disclosure and a method of its use provide a twisted- or 3-dimensional guide path “P” for a wire rope or wireline “W”, the guide path being define by a plurality of sheaves 40 arranged sequentially, the wrap angle being on a same portion of each sheave as any other sheave of the plurality. The guide path may start at a first sheave located at coordinates (X, Y, Z)_(n) and may end at a last sheave with coordinates (X, Y Z)_(N), where n=1 to N, N is the total number of sheaves defining the guide path; the coordinates (X, Y Z) indicate a center point of the respective sheave; and (X, Y, Z)_(n)≠(X, Y Z)_(N).

In embodiments, the apparatus 10 may include a housing 20 that contains a plurality of sheaves 40 configured to receive the wire rope or wireline W, the sheaves 40 arranged sequentially along a predetermined guide path P. The wire rope or wireline may be routed through the guide path provided by the sheaves 40 from the first to the last sheave of the plurality (or vice versa). In embodiments, no back-and-forth reeving of the wire rope or wireline W is required for the guide path P, nor are alternating circumferential portions of adjacent sheaves 40 used for the wrap angle α. Instead, reeving is along a same side circumferential portion (arcuate segment) 47 of each sheave 40 as any other sheave 40 of the plurality. The wrap angle α may be any wrap angle suitable for a given wire rope or wire line application. In some embodiments, the wrap angle α may be in a range of 5° to 30°, there being discrete values and subranges within this broader range.

The housing 20 may be configured as a frame 23 that includes opposing plates or sidewalls 25L, 25R, with the frame 23 being partially or completely open along its top and bottom 27T, 27B. The frame 23 may also be partially or completely closed along its top and bottom. A proximal end 21 of the housing 20 may be at a first elevation and the distal end 31 of the housing 20 may be at a second elevation. The first elevation may be a higher elevation and the second elevation may be a lower elevation (or vice versa).

Each sheave 40 has a width sized to receive a predetermined wire rope or wireline size and a diameter sized to provide the predetermined wrap angle α. Generally accepted engineering practices and principles may be used to determine the proper sheave width, diameter and wrap angle as well as other parameters such as fleet angle. For each sheave 40, a respective center point 41 is located at a respective X, Y Z coordinate along the guide path. The guide path P may be represented by a central longitudinal centerline 29 of the housing 20 between the proximal and distal ends 21, 31 of the housing 20. The center points 41 of the sheaves 40 lie along the central longitudinal centerline 29 of the housing 20. The center point 41 or centerline 45 of adjacent sheaves S_(i), S_(i+1) of the plurality of sheaves 40 may be at a same or different elevations relative to one another.

In embodiments a centerline 45 of the sheave S_(i+1) of the plurality of sheaves 40 may be at a first elevation and a centerline 45 of the sheave S_(i) of the plurality of sheaves 40 is at a second elevation. The first elevation may be a higher elevation and the second elevation may be a lower elevation (or vice versa). The sheaves S₂ to S_(N-1) may be at successively decrementing elevations in between the first and last sheave S₁, S_(N). In some embodiments, two or more of the sheaves S₁ to S_(N) are at a same elevation. The sheave S_(N) may be oriented so the wireline leads out at or close to an orientation of an entry point to a piece of equipment. The wire rope or wireline may lead out at or close to the entry point in the X or Y plane. Where the apparatus is located at or above the entry point, the wire rope or wireline may enter the entry point and follow a path oriented in a Z direction. For example, the wireline may enter a gooseneck of a top drive the same or similar to those used to lift, lower, and rotate drillstring.

Sheave pins 43, that pass through the center point 41 of the sheaves 40, may extend between the sidewalls 25. Each sheave pin 43 provides, for its respective sheave 40, a centerline or axis of rotation 41. A planar orientation of each sheave 40 lies perpendicular to its respective axis of rotation 41, the guide path following this planar orientation. Unlike the prior art, the orientation of the second sheave S₂ is angled or twisted a predetermined number of degrees β from that of the first sheave S₁ so that the second sheave lies in a second different planar orientation relative to that of the first sheave. The same is true of the orientation of the third sheave S₃ relative to that of the second, and so on throughout the plurality of sheaves. The end result is that sheave 40 is twisted relative to any adjacent sheave 40 along the guide path.

The twist angle may be an oblique angle β. In embodiments, the same twist angle β is used for each sheave 40, with the actual twist angle of each sheave S_(1+i), relative to the orientation of the first sheave S₁ being (1+i)β, where i=2 to N. By way of a non-limiting example, β may be in a range of 5° to 25°, 10° to 20°, 11° to 19°, 12° to 18°, 13° to 17°, or 14° to 16°, there being discrete angles and subranges within each broader range.

Because the orientation of each sheave 40 is twisted or angled relative to each adjacent sheave 40 of the plurality, the plurality of sheaves 40 and a portion of the housing 20 located between the proximal and distal ends 21, 31 extends or twists through a total angle Nβ. In other words, the last sheave S_(N) of the plurality may be offset Nβ from the first sheave S₁ of the plurality in the X or Y plane. In general terms, an orientation of sheave S_(n+1) of the plurality of sheaves is at the angle β relative to an orientation of sheave S_(n) of the plurality of sheaves, where n=1 to N. The total amount of twist over a subset of “n” sheaves is (n−1)β, where n=2 to N, N being the total number of sheaves. The total angle Nβ may be in a range of 10° to 90°, there being discrete angles and subranges within each broader range

The twisting can permit a number of different locations for the apparatus relative to a wireline entry point to a piece of equipment. Similar to other parameters of the apparatus 10, generally accepted engineering practices and principles may be used to determine the twist angle β and total amount of twist (and therefore number of sheaves) required over the guide path. By way of a non-limiting example, the total amount of twist may be in a range of 30° to 90°, there being discrete values and subranges within this broader range. The twisting also allows, for a given same application, a lower number of sheaves, more entry point locations, and a more desired entry point location than that of US 2015/0013992 A1 to Mann et al.

In embodiments, a larger diameter sheave 60 may be located immediately upstream of sheave S₁ (or downstream of sheave S_(N)) of the plurality of sheaves 40. Each sheave 40 has a width sized to receive a predetermined wire rope or wireline size and a diameter sized to provide the predetermined wrap angle α. Generally accepted engineering practices and principles may be used to determine the proper sheave width, diameter and wrap angle as well as other parameters such as fleet angle. Similar to sheaves 40, a sheave pin 63 passes through the center point 61 of the sheave 60. The sheave pin 63 provides, for the sheave 60, a centerline or axis of rotation 65. A planar orientation of the sheave 60 lies perpendicular to its respective axis of rotation 65, the wire rope or wireline following this planar orientation to the first sheave S₁ of the plurality of sheaves 40. The planar orientation of the first sheave S1 may be the same or different than that of the sheave 60.

In some embodiments, sheave 60 and housing 20 are connected to a top drive like those found on a drilling rig and configured for lifting, lowering, and rotating drill pipe. The wireline apparatus 10 comprising sheaves 40 and 60 may be located toward an upper end of the top drive. The apparatus 10 may be arranged so that the wireline enters a gooseneck of the top drive. All wireline tension may be reacted on a motor tower.

While the disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims.

The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for” or “step for” performing a function, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f). 

What is claimed:
 1. A wireline apparatus comprising: a housing including a proximal end and a distal end; a plurality of sheaves contained by the housing and arranged sequentially between the proximal and distal ends of the housing along a longitudinal centerline of the housing, each sheave having a centerline coaxial to an axis of rotation and an orientation in a plane perpendicular to the centerline, each sheave further having a width sized to receive a predetermined wireline size and a diameter sized to provide a predetermined wrap angle α; an orientation of sheave S_(i+1) of the plurality of sheaves being at an oblique angle β relative to an orientation of sheave S_(i) of the plurality of sheaves, where i=1 to N, N being the total number of sheaves; the plurality of sheaves and a portion of the housing located between the proximal and distal ends extending through a total angle Nβ.
 2. The wireline apparatus of claim 1, further comprising: another sheave located upstream of sheave S₁ of the plurality of sheaves, the another sheave having a centerline coaxial to an axis of rotation and an orientation in a plane perpendicular to the centerline, the another sheave further having a width sized to receive the predetermined wireline size and a larger diameter and wrap angle than that of the plurality of sheaves.
 3. The wireline apparatus of claim 2, further comprising: the another sheave and the sheave S₁ of the plurality of sheaves having a same planar orientation relative to one another.
 4. The wireline apparatus of claim 2, further comprising: the another sheave and the sheave S₁ of the plurality of sheaves having a different planar orientation relative to one another.
 5. The wireline apparatus of claim 1, wherein the proximal end of the housing is at a first elevation and the distal end of the housing is at a second different elevation.
 6. The wireline apparatus of claim 1, wherein a horizontal centerline of the sheave S_(i+1) of the plurality of sheaves is at a first elevation and a horizontal centerline of the sheave S_(i) of the plurality of sheaves is at a second different elevation.
 7. The wireline apparatus of claim 1, further comprising: a top drive configured for lifting, lowering, and rotating drill pipe; the wireline apparatus being connected to the top drive.
 8. The wireline apparatus of claim 7, further comprising: the wireline apparatus located toward an upper end of the top drive.
 9. The wireline apparatus of claim 1, the oblique angle β being in a range of 1° to °
 30. 10. The wireline apparatus of claim 1, the total angle Nβ being in a range of 10° to 90°.
 11. A method of routing a wireline through a piece of hoisting equipment, the method comprising: routing a wireline about a larger diameter sheave and a plurality of smaller diameter sheaves, the plurality of smaller diameter sheaves arranged sequentially along a longitudinal centerline of a housing containing the smaller diameter sheaves; the larger and smaller diameter sheaves each having a centerline coaxial to an axis of rotation and an orientation in a plane perpendicular to the centerline; an orientation of sheave S_(i+1) of the plurality of sheaves being at an oblique angle β relative to an orientation of sheave S_(i) of the plurality of sheaves, where i=1 to N, N being the total number of sheaves; the plurality of smaller diameter sheaves and a portion of the housing located between the proximal and distal ends extending through a total angle Nβ.
 12. The method of claim 11, wherein the larger diameter sheave is located upstream of sheave S1 of the plurality of smaller diameter sheaves.
 13. The method of claim 11, wherein the larger diameter sheave and sheave S₁ of the plurality of smaller diameter sheaves have a same planar orientation relative to one another.
 14. The method of claim 11, wherein the larger diameter sheave and sheave S₁ of the plurality of smaller diameter sheaves have a different planar orientation relative to one another.
 15. The method of claim 11, wherein the proximal end of the housing is at a first elevation and the distal end of the sheave housing is at a second different elevation.
 16. The method of claim 11, wherein a horizontal centerline of the sheave S_(i+1) of the plurality of sheaves is at a first elevation and a horizontal centerline of the sheave S_(i) of the plurality of sheaves is at a second different elevation.
 17. The method of claim 11, wherein further the wireline apparatus is connected to a top drive of a drilling rig.
 18. The method of claim 17, wherein the wireline apparatus is located toward an upper end of the top drive.
 19. The method of claim 11, the oblique angle β being in a range of 1° to °
 30. 20. The method of claim 11, the total angle Nβ being in a range of 10° to 90°. 